Foundation base for mounting wind turbines in an aquatic bed and method for manufacturing said foundation

ABSTRACT

The invention relates to a foundation base for mounting wind turbines in an aquatic bed and a method for manufacturing said foundation, formed by a conical structure which is made up of an assembly of columns ( 1 ) like generatrices, arranged between an upper apex core ( 2 ) and a lower annular footing ( 3 ), the constructive mounting of said assembly being carried out on an annular mold ( 8 ) which is arranged floating in the water, in which the annular footing ( 3 ) is formed, with the attachment thereon of the columns ( 1 ), which are held in the constructive formation of the structural assembly by means of a support jig ( 10 ).

FIELD OF THE ART

The present invention relates to the installation of wind turbines in aquatic beds, proposing for such purpose a foundation base made with structural features facilitating the construction in port installations, for the transport from the installation site and the mooring in said site by means of an aquatic vehicle.

STATE OF THE ART

For the production of electrical energy by means of the exploitation of wind, the use of wind turbines located in aquatic beds, wherein wind regimes greater than those on land are obtained due to the low roughness of the water surface, in addition to having large free spaces for placing the wind turbines, is known.

One condition of the wind turbines of this type is that they must be suitably anchored in the aquatic floor in order to ensure the installation in a stable manner, the use of foundations formed by a large concrete block is known for that purpose, which block is moored and seated in the installation site to then arrange the corresponding wind turbine thereon.

Said foundations are usually constructed in port sites or coastal areas, from which they are transported by means of an aquatic vehicle for the mooring in the application site.

Given the dimensions and the weight of these foundations, their manufacture is very expensive and cranes with high load capacity are required for the handling, which cranes must in turn be transported to the installation site, large vessels which generally come from the gas or petroleum industry being used for that purpose, resulting in a very high cost.

In this sense, European patent EP 1,777,348, for example, describes a gravity seating foundation and the method for installing said foundation in an aquatic bed, using to that end an adapted vessel which carries out the conditioning of the aquatic floor, whereas the mooring of the foundation on the conditioned aquatic bed is carried out with another vessel provided with a system of cranes; which solution entails process cost and slowness problems derived from the multiple independent operative means which are used.

OBJECT OF THE INVENTION

According to the invention, a foundation base for mounting wind turbines in an aquatic bed is proposed, with a structural embodiment facilitating the constructive formation of said foundation in a port site and the transport for the installation mooring by means of a vehicle capable of carrying the foundation and depositing it by itself in the aquatic floor.

This foundation object of the invention consists of a conical structure formed by a assembly of columns like generatrices arranged between an upper apex core and a lower annular footing, the upper apex core being formed by a cylindrical element with an upper base for the securing of the tower of the wind turbine to be installed and with a lower base on which the columns of the conical structure are secured by means of threaded elements, whereas the lower footing, which can be circular or polygonal, is formed by a concrete ring, in which the lower ends of the columns of the conical structure are embedded.

The component columns of the conical structure can be metallic (for example of steel), or of concrete reinforced with metallic bars, threaded rods projecting, in any case, through the upper end in order to establish the securing with respect to the apex core of the structure, whereas hooks come out through the lower end of said columns in order to establish therewith a mounting fastening with respect to metallic framework bars which are arranged in the constructive formation of the lower annular footing of the structure.

A structural assembly with a simple construction and with the necessary weight is thus obtained in order to determine, as a result of its configuration, a seat for the support on the aquatic floors with the required stability to serve a supporting base for a wind turbine.

In the annular footing of the structural assembly there are included, however, vertical piling tubes through which it is possible to establish a fastening anchorage by means of piles on the aquatic floor, when the conditions require it, for example when the seating site is of a soft nature.

By means of the columns of the conical structure the foundation furthermore determines an ice breakup function, said columns of the conical structure being provided for such purpose according to a sharp edge configuration, for example, with a square- or triangular-shaped section, having an advantageous application for the installation in geographical places with a cold climate where the aquatic surfaces usually freeze into ice.

The assembly of the foundation thus formed determines a hollow structure in the form of a cage, which in the application arrangement can be used for exploitation in secondary uses, such as for example, by means of covering with a metallic net in order to determine a fish farm therein.

The constructive formation of the structure of the foundation is carried out by arranging in the water a floating annular mold and a jig in the form of an umbrella structure axially in vertical with respect to such mold, the component columns of the conical structure being incorporated supported in an inclined position on the arms of the jig, with the upper end thereof secured to the apex core for the formation of the structure, and with the lower end of said columns introduced in the floating annular mold, such that by concreting in the mold the formation of the constructive block of the annular footing, the structure of the foundation is formed in an integral assembly.

Once so, on the assembly of the component columns of the conical structure there are arranged peripheral reinforcement rings to prevent the buckling of the mentioned columns, and the jig in the form of an umbrella structure is extracted through the tubular apex core of the structure.

For the transport to the installation site, the foundation thus constructed is suspended, by means of a capstan, from an inverted V-shaped structure arranged on an aquatic vehicle, such that by lifting the foundation the lower footing thereof comes out of the formation mold, which remains floating in the water.

In these conditions, by means of the aquatic vehicle the foundation is taken to the installation site, wherein the actual transport vehicle is submersed, such vehicle itself carrying out the preparation of the aquatic floor with means which it has incorporated therein, and immediately the seating of the foundation in the prepared area, such that the seating of the foundation is carried out without giving time for the area prepared for that purpose to undergo alterations.

After the foundation is deposited, the aquatic vehicle refloats to the surface, being able to be used to carry with itself the wind turbine to be installed and place it on the foundation.

Therefore, truly advantageous features in the structure and construction of a supporting foundation for the installation of wind turbines in aquatic beds are obtained with the object of the invention, this solution acquiring its own identity and a preferred character with respect to the known foundations for this function.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of the floating mold which is used for the constructive formation of the foundation object of the invention, according to a circular embodiment.

FIG. 2 is a perspective view of the floating mold with the jig in the form of an umbrella structure which is used to support the component columns of the conical structure in the constructive formation of the foundation.

FIG. 3 is a perspective view of the mounting of a column of the conical structure of the foundation.

FIG. 4 is a perspective view of the arrangement of the assembly of the conical structure in the formation of the foundation.

FIG. 5 is a perspective view of the assembly of the foundation formed on the floating mold, with the jig in the form of an umbrella structure in the inside.

FIG. 6 is a perspective view of the extraction of the jig in the form of a folded umbrella structure used for the constructive formation of the foundation.

FIG. 7 is a sectional detail of the apex of the foundation, with the jig in the form of an umbrella structure included through the tubular apex core.

FIG. 8 is detail like that of the previous figure, in the phase of extraction of the jig in the form of a folded umbrella structure through the tubular apex core.

FIG. 9 is an example in perspective view of a column with a square section for the formation of the conical structure of the foundation.

FIG. 9A is an example in perspective view of a column with a triangular section for the formation of the conical structure of the foundation with a great effect of the ice breakup function.

FIG. 10 is a sectional detail of the securing of a column of the conical structure on the apex core of the foundation.

FIG. 11 is a detail of the previous figure in an exploded position.

FIG. 12 shows a port installation with the mold for manufacturing the foundation on water.

FIG. 13 is a depiction like the previous one, with the jig in the form of an umbrella structure on the floating mold.

FIG. 14 is a depiction like the previous ones, with the assembly of the foundation formed on the floating mold.

FIG. 15 is a depiction of the collection of the foundation by means of an aquatic transport vehicle.

FIG. 16 shows the lifting of the foundation with respect to the floating mold in order to be suspended in the transport position.

FIG. 17 is a depiction of the submersed position of the aquatic transport vehicle of the foundation, in the operation of preparation of the aquatic floor.

FIG. 18 is a depiction of the operation of the seating of the foundation in the prepared area of the aquatic floor.

FIG. 19 is a depiction of the refloating of the aquatic vehicle after the foundation is deposited.

FIG. 20 is a perspective view of the foundation with the corresponding wind turbine placed thereon and the aquatic vehicle in the position of withdrawal from the installation area.

FIG. 21 is a view of the arrangement of the foundation in the aquatic floor, with anchorage by means of fastening piles.

FIG. 22 is a sectional detail of the formation of the lower footing of the foundation.

FIG. 23 is a sectional detail of the seat of the footing of the foundation with a fastening pile.

FIG. 24 is an example in perspective view of the formation of the foundation with the lower footing with a polygonal shape and the columns of the conical structure with a triangular section.

FIG. 25 is a plan view of the embodiment of the foundation according to the example of the previous figure.

DETAILED DESCRIPTION OF THE INVENTION

The object of the invention relates to a foundation base for supporting wind turbines in aquatic beds, with features simplifying the constructive embodiment and facilitating the application of a method for manufacturing in port installations, for the transport of the constructed foundation and seating thereof in the installation site by means of an aquatic vehicle.

The proposed foundation is made up of a conical structure formed by an assembly of columns (1) arranged like generatrices between an upper apex core (2) and a lower annular footing (3).

The columns (1) can be metallic, for example of steel, or of concrete, having threaded rods (1.1) in the upper end and hooks (1.2) in the lower end, as observed in the example depicted in FIG. 9.

Said columns (1) can have any configuration, but they are particularly provided with a polygonal section, such that they determine sharp edges capable of carrying out an ice breakup function, for example with a configuration with a square section, like the example of FIG. 9, or with a configuration with a triangular section, like the example of FIG. 9A, the latter embodiment being particularly advantageous for installations of the foundation in places with a cold climate which are prone to the formation of ice in the aquatic surface.

The apex core (2) is a cylindrical element, with an upper base (2.1) for the securing of the tower of the wind turbine (4) which is arranged on the foundation, as observed in FIG. 20, whereas in the lower part said element of the apex core (2) determines a base (2.2) intended for the securing of the columns (1) of the conical structure, by means of the threaded rods (1.1) of the upper end thereof, as observed in FIGS. 10 and 11.

The footing (3) of the foundation is formed by an annular block formed from concrete, with a metallic framework (3.1) therein, said block of the footing (3) being attached to the columns (1) of the conical structure by means of the inclusion of the lower end of the mentioned columns (1) in the material of this block of the footing (3), after attaching the hooks (1.2) of the columns (1) on the metallic framework (3.1) of the footing (3), as observed in FIG. 22.

Said footing (3) of the foundation can have an annular shape according to any contour configuration, without this altering the concept, for example according to a circular contour, like in FIGS. 1 to 6, or according to a polygonal contour, like in FIGS. 24 and 25, without these examples being limiting.

Thus, the foundation determines an integral structural assembly, with a weight and a base allowing the gravity seating in aquatic floors (5), to support a wind turbine (4) arranged thereon. Nevertheless, for the cases of application of seating on soft aquatic floors (5), in the constructive block of the footing (3) there are arranged vertical tubes (6), through which it is possible to establish an anchorage securing by means of piles (7) in order to ensure the fastening, as observed in FIGS. 21 and 23.

The constructive formation of the foundation is carried out on a floating annular mold (8), with a circular contour like the one depicted in FIG. 1 or with a polygonal contour, which is arranged on the water (9) in a port installation, as observed in FIG. 12, axially placing in vertical on said mold (8) a jig (10) formed by a mast (10.1) and a series of radial articulated arms (10.2) on the mentioned mast (10.1), in the form of an umbrella structure, as observed in FIGS. 2 and 13.

The jig (10) in the form of an umbrella structure is included through the cylindrical element of the apex core (2) intended for assembling the foundation, said element of the apex core (2) being in the upper end of the mast (10.1) of the jig (10).

The columns (1) are mounted on this assembly to form the conical structure of the foundation, the mentioned columns (1) being arranged, as shown in FIGS. 3 and 4, supported on the radial arms (10.2) of the jig (10), with the upper end thereof attached to the lower base (2.2) of the apex core (2) and with the lower end of said columns (1) entering the annular mold (8), such that, once so, the concreting of formation of the block of the footing (3) is carried out in the mold (8), whereby the conical structure is formed.

To prevent the deformation of the columns (1) by buckling, reinforcement rings (11) are arranged on the assembly of the conical structure formed by said columns (1), as observed in FIG. 5, said rings (11) being fixed on the columns (1) by any fastening means which allow establishing the rigidity of the assembly.

Once the foundation is completely formed in the indicated manner, the jig (10) is removed, folding the arms (10.2) over the mast (10.1) for that purpose, such that in this position said jig (10) is extracted through the tubular element of the apex core (2) of the foundation, as shown in FIGS. 6 and 8.

In these conditions, the foundation formed remains on the mold (8), floating in the water (9), such that in this arrangement the foundation can be collected by an aquatic vehicle (12), as shown in FIG. 15, for the transport to the installation site. To that end, an aquatic vehicle (12) formed by two floats (13), such as a catamaran, is provided, there being an inverted V-shaped structure (14) on the mentioned floats (13), which structure incorporates a capstan (15) in the apex, by means of which the foundation is held and lifted, as shown in FIG. 16.

When the foundation is lifted, the footing (3) thereof comes out of the mold (8), the latter remaining on the water (9), whereas the foundation remains suspended from the structure (14) of the aquatic vehicle (12), wherein it is maintained stable by means of side stops (16) so that it does not swing due to the movements of the vehicle (12) on the water (9) during the transport.

In the installation site of the foundation, the aquatic vehicle (12) is submersed, being supported in the aquatic floor (5) by means of telescopic legs (17), between which there is arranged a transverse bridge (18) having a head (19) which can incorporate tools of different types, by means of which the preparation of the area of the aquatic floor (5) intended for seating the foundation is carried out, as shown in FIG. 17.

Once the corresponding area of the aquatic floor (5) is prepared, the foundation is placed thereon by simply allowing it to move down by means of the capstan (15), until the seating, as shown in FIG. 18, such that the preparation of the area of the aquatic floor (5) and the seating of the foundation are carried out in immediately consecutive operations, without time, therefore, for the prepared area to undergo alterations due to the movements of the water (9), which ensures the perfect seating of the foundation.

After the foundation is deposited, the aquatic vehicle (12) refloats to the surface, for its transport back to the port installations, from where with this same vehicle (12) or another similar one, the wind turbine (4) to be installed can be taken for its placement on the foundation arranged on the aquatic floor (5) in the installation site. 

1. A foundation base for mounting wind turbines in an aquatic bed, of the type intended to be seated on the aquatic floor in the installation site, in order to place a wind turbine thereon, characterized in that it consists of a conical structure comprising an assembly of columns (1) like generatrices, arranged between an upper apex core (2) and a lower annular footing (3), determining a structural assembly in the form of a cage, with the upper ends of the columns (1) being secured with respect to the apex core (2), whereas the lower end thereof is introduced in the constructive formation of the annular footing (3).
 2. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that the apex core (2) is formed by a tubular element with an upper base (2.1) for the securing of the wind turbine to be supported with the foundation and a lower base (2.2) with respect to which the securing of the columns (1) is established.
 3. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that the footing (3) is formed by annular concrete block, with a circular or polygonal contour, with a metallic framework (3.1) in the inside, the lower end of the columns (1) being included in said concrete block, with fastenings for securing on the metallic framework (3.1).
 4. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that the columns (1) have threaded rods in the upper end, by means of which the securing with respect to the base (2.2) of apex core (2) is established.
 5. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that the columns (1) have hooks (1.2) in the lower end, by means of which the fastenings for securing on the metallic framework (3.1) of the footing (3) are established.
 6. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that the columns (1) have a polygonal section, for example a square triangular section, determining sharp edges allowing an ice breakup function of the structural assembly of the foundation.
 7. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that vertical tubes (6) are included in the constructive block of the footing (3) for the anchorage of the foundation by means of piles in the installation site.
 8. The foundation base for mounting wind turbines in an aquatic bed according to claim 1, characterized in that on the conical structure formed by the columns (1) there are arranged reinforcement rings (11) which are fixed on the mentioned columns (1), to prevent the buckling thereof.
 9. A method for manufacturing a foundation base for mounting wind turbines in an aquatic bed, determining a conical structure which is formed by an assembly of columns (1) like generatrices, arranged between an upper apex core (2) and a lower annular footing (3), characterized in that the constructive mounting is carried out on an annular mold (8), with a circular or polygonal contour, which is arranged floating in the water (9), on which there is incorporated a jig (10) consisting of a mast (10.1) and articulated radial arms (10.2) thereon, said jig (10) being included through the apex core (2) of formation of the foundation, with respect to which the columns (1) of formation of the conical structure are secured at the upper end, which columns are supported in the radial arms (10.1) of the jig (10), with the lower end thereof entering in the mold (8), in which the concreting of formation of the footing (3) is carried out, covering said lower end of the columns (1) with the constructive concrete.
 10. The method for manufacturing a foundation base for mounting wind turbines in an aquatic bed according to claim 9, characterized in that once the constructive formation of the foundation is carried out, the jig (10) is removed by means of the extraction thereof in a folded position through the apex core (2).
 11. The method for manufacturing a foundation base for mounting wind turbines in an aquatic bed according to claim 9, characterized in that the demolding with respect to the mold (8) is carried out by lifting the assembly of the foundation formed, such that the footing (3) comes out of said mold (8), which remains floating in the water (9). 